U.S. patent number 11,448,370 [Application Number 17/164,052] was granted by the patent office on 2022-09-20 for led light bulb.
This patent grant is currently assigned to XIAMEN ECO LIGHTING CO. LTD.. The grantee listed for this patent is XIAMEN ECO LIGHTING CO. LTD.. Invention is credited to Yanzeng Gao, Hongkui Jiang.
United States Patent |
11,448,370 |
Jiang , et al. |
September 20, 2022 |
LED light bulb
Abstract
The lighting device includes at least one filament module, a
base, at least one pillar, and a base. The filament module includes
more than two filaments. Each filament includes a substrate,
multiple LED chips, a phosphor film, a top extended electrode, and
a bottom extended electrode. Multiple LED chips are mounted on the
substrate. The phosphor film covers the substrate and multiple LED
chips. The top extended electrode and bottom extended electrode are
connected to two ends of the substrate respectively. At least part
of top extended electrode and bottom extended electrode are not
covered by the phosphor film, and each top extended electrode of
the filaments is fixed together.
Inventors: |
Jiang; Hongkui (Xiamen,
CN), Gao; Yanzeng (Xiamen, CN) |
Applicant: |
Name |
City |
State |
Country |
Type |
XIAMEN ECO LIGHTING CO. LTD. |
Xiamen |
N/A |
CN |
|
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Assignee: |
XIAMEN ECO LIGHTING CO. LTD.
(Xiamen, CN)
|
Family
ID: |
1000006573946 |
Appl.
No.: |
17/164,052 |
Filed: |
February 1, 2021 |
Prior Publication Data
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|
Document
Identifier |
Publication Date |
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US 20210148519 A1 |
May 20, 2021 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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16725156 |
Dec 23, 2019 |
10935189 |
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15944757 |
Feb 4, 2020 |
10551007 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21K
9/237 (20160801); F21K 9/235 (20160801); F21K
9/90 (20130101); F21K 9/238 (20160801); F21V
19/003 (20130101); F21Y 2115/10 (20160801) |
Current International
Class: |
F21K
9/238 (20160101); F21K 9/237 (20160101); F21K
9/90 (20160101); F21V 19/00 (20060101); F21K
9/235 (20160101) |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Hines; Anne M
Assistant Examiner: Diaz; Jose M
Attorney, Agent or Firm: Shih; Chun-Ming Lanway IPR
Services
Parent Case Text
RELATED APPLICATION
The present application is a continuation application of U.S.
application Ser. No. 16/725,156, which is a continued application
of U.S. application Ser. No. 15/944,757.
Claims
The invention claimed is:
1. A LED light bulb, comprising: multiple filaments, wherein each
filament comprises a substrate, multiple LED chips, a phosphor film
on two sides of the substrate, a top extended electrode, and a
bottom extended electrode, multiple LED chips are mounted on the
substrate, the phosphor film covers the substrate and multiple LED
chips, the top extended electrode and the bottom extended electrode
are connected to two ends of the substrate respectively, at least
part of the top extended electrode and the bottom extended
electrode are not covered by the phosphor film, and each top
extended electrode of the filaments is fixed together; a base; at
least one pillar, wherein the bottom of the pillar is connected to
the base, multiple top extended electrodes of the multiple
filaments hang on the top of the pillar; and a base, wherein the
base contains the driver circuit, the base is used to connect to
the power, wherein the top of the pillar is used to support the
multiple filaments.
2. The LED light bulb of claim 1, wherein multiple top extended
electrodes of the multiple filaments connect to each other, then
the combination of multiple top extended electrodes connects to the
top of the pillar.
3. The LED light bulb of claim 1, wherein multiple top extended
electrodes of the multiple filaments are integrally formed.
4. The LED light bulb of claim 3, wherein a connection of the top
extended electrodes of the multiple filaments have a ring, the ring
is put into the top of the pillar.
5. The LED light bulb of claim 1, wherein the top extended
electrodes of the multiple filaments have a ring, the ring is put
into the top of the pillar.
6. The LED light bulb of claim 1, wherein the number of the pillar
is more than two, and the multiple filaments hang on the tops of
the pillars.
7. The LED light bulb of claim 1, wherein the pillar is a thin
piece of metal.
8. The LED light bulb of claim 1, wherein an insulation part of the
top of the pillar is made of glass.
9. The LED light bulb of claim 1, wherein the pillar in the area of
insulation part is all made of glass.
10. The LED light bulb of claim 1, wherein an insulation part of
the top of the pillar is made of plastic.
11. The LED light bulb of claim 1, wherein the support structure of
the pillar is a slot at an insulation part of the top of the
pillar.
12. The LED light bulb of claim 1, wherein the support part of the
pillar is an extended component set in an insulation part of the
top of the pillar.
13. The LED light bulb of claim 12, wherein the extended component
is a metal stick, the extended component includes an inner part and
an extended part, the inner part of the extended component is set
in the insulation part, the extended part of the extended component
is stretched away from the insulation part, the top extended
electrodes of the multiple filaments hang on the extended part of
the extended component.
14. The LED light bulb of claim 1, further comprising a bottom
electrical connection structure, the bottom electrical connection
structure extends from the base, the bottom electrical connection
structure electrically connects to the driver circuit, the bottom
extended electrodes of the multiple filaments electrically connect
to the bottom electrical connection structure, and the multiple
filaments are electrically connected in series or parallel.
15. The LED light bulb of claim 14, wherein the bottom electrical
connection structure has an annular metallic strip, by cutting off
the annular metallic strip, the multiple filaments are electrically
connected in series or parallel.
16. The LED light bulb of claim 15, wherein the bottom extended
electrodes of the multiple filaments are fixed to the bottom
electrical connection structure and thus to allow the angle between
each filament and the pillar to be more than fifteen degrees.
Description
FIELD OF THE INVENTION
The present invention relates to a lighting device and a
manufacturing method of lighting devices, and more particularly to
a LED (Light emitting diode) lighting device and a manufacturing
method of LED lighting devices.
BACKGROUND
Lighting is an important part of human life. Since Thomas Edison
has invented electric lighting, the life of human being was widely
changed. With the improvement in LED (Light emitting diode)
technology and the decrease in cost, LED technology rapidly extends
to various light fixtures and applications.
Compared with traditional incandescent light bulbs, LED usually has
better luminous efficacy. However, LED components have limitations
in heat resistance. If the problems of heat dissipation can be
solved effectively, the life span of LED and the stability of light
fixtures would be greatly improved.
Light bulbs are an important part of a light fixture. Because light
bulbs are used for a long period, people have given impressions and
preferences of the shape of light bulbs. Currently there are LED
light bulbs designed to resemble traditional incandescent light
bulbs in the market. However, the production process of LED light
bulbs similar to incandescent light bulbs in appearance often faces
the problems of weak structures and complicate assembly.
The present invention focuses on the technical problems of these
kind of light bulbs. The present invention shows improvements in
cost, reliability of products, and production cost.
SUMMARY OF INVENTION
The present invention provides an improved lighting device
according to the first embodiment of the present invention. The
lighting device includes at least one filament module, a base, at
least one pillar, and a base.
The filament module includes more than two filaments. Each filament
includes a substrate, multiple LED chips, a phosphor film, a top
extended electrode, and a bottom extended electrode. Multiple LED
chips are mounted on the substrate. The phosphor film covers the
substrate and multiple LED chips. The top extended electrode and
bottom extended electrode are connected to two ends of the
substrate respectively. At least part of top extended electrode and
bottom extended electrode are not covered by the phosphor film, and
each top extended electrode of the filaments is fixed together.
The bottom of the pillar is connected to the base. Multiple top
extended electrodes of the filaments of the filament module hang on
the top of the pillar. A driver circuit electrically connects to
multiple bottom extended electrodes of the filaments of the
filament module. The base contains the driver circuit. The base is
used to connect to the power.
In some embodiments, multiple top extended electrodes of the
filaments of the filament module may connect to each other, then
the combination of multiple top extended electrodes connects to the
top of the pillar. In other words, the highest parts of the
filaments may be assembled first, then the highest parts of the
filaments are fixed to the top of the pillar.
In some embodiments, multiple top extended electrodes of the
filaments of the filament module are integrally formed. In this
kind of manufacturing method, the stability and conductivity of the
filament are further improved, and the unnecessary problem of
temperature increase gets better.
In some embodiments, the connection part of the top extended
electrodes of multiple filaments may have a ring. The ring is put
into the top of the pillar.
In some embodiments, the top extended electrode of the filament is
made with a ring, and the top of the pillar is inserted into the
ring. In other words, compared with traditional method of fixing
the stick electrodes by welding, this method further improves the
stability of the filaments.
In some embodiments, the number of the pillar is more than two, and
multiple fila
In some embodiments, the pillar is a thin piece of metal. For
example, the pillar may be made of iron-nickel alloys with certain
hardness.
In some embodiments, the top of the pillar includes an insulation
part. The insulation part has a support structure used to hold
multiple top extended electrodes of the filaments of the filament
module. In other words, the insulation part avoids a short circuit,
causing by assembly or vibration, when certain filaments are
electrically connected.
In some embodiments, the above-mentioned insulation part may be
made of glass.
In some embodiments, the pillar in the area of insulation part may
be all made of glass.
In some embodiments, the insulation part is made of plastic.
Plastic may further reduce the overall cost. Plastic are easier to
produce a relatively complicated stand, and the stand is used to
support and fix the connection parts of the filaments.
In some embodiments, the support structure is a slot at the top of
the insulation part. In other words, the mounting of the filaments
becomes more stable with gloves, holes, and soon.
In some embodiments, the support part of the pillar is an extended
component set in the insulation part. For example, the support part
may be made out of metal sticks, and the pillar may be made of
plastic or metal. The support part, like metal sticks and so on, is
set in the pillar in the production process of the pillar. In this
way, the stability is improved, and the complexity of assembly is
reduced.
In some embodiments, the extended component is a metal stick. The
extended component includes an inner part and an extended part. The
inner part of the extended component is set in the insulation part.
The extended part of the extended component is stretched away from
the insulation part. The top extended electrodes of multiple
filaments of the filament module hang on the extended part of the
extended component.
In some embodiments, a bottom electrical connection structure
extends from the base. The bottom electrical connection structure
electrically connects to the driver circuit. The bottom extended
electrodes of multiple filaments of the filament module
electrically connect to the bottom electrical connection structure,
and multiple filaments are electrically connected in series or
parallel.
In some embodiments, the bottom electrical connection structure has
an annular metallic strip. By cutting off the annular metallic
strip, multiple filaments are electrically connected in series or
parallel.
In some embodiments, the bottom extended electrodes of multiple
filaments are fixed to the bottom electrical connection structure
and thus to allow the angle between each filament and the pillar to
be more than fifteen degrees.
In some embodiments, an insulator is put over a pair of connection
parts of the top extended electrodes of the filaments, and another
a pair of connection parts of the top extended electrodes of the
filaments are fixed to the pillar over the insulator.
The present invention provides a manufacturing method of a lighting
device according to another view of the present invention. The
manufacturing method includes steps as follows.
A filament module is provided. The filament module includes at
least two filaments. The filament includes a substrate, multiple
LED chips, a phosphor film, a top extended electrode, and a bottom
extended electrode. Multiple LED chips are mounted on the
substrate. The phosphor film covers the substrate and multiple LED
chips. The top extended electrode and bottom extended electrode are
connected to two ends of the substrate respectively. At least part
of top extended electrode and bottom extended electrode are not
covered by the phosphor film. Each top extended electrode of the
filaments is fixed together.
One or multiple filament modules are fixed to the pillar of the
lighting device. The pillar is mounted on the base of the lighting
device.
In some embodiments, this manufacturing method further includes a
producing way of cutting a metal plate to produce the substrate,
the top extended electrode, and the bottom extended electrode of
the filament modules.
According to different embodiments as above, the present invention
makes it possible to decrease the cost with varying degrees,
improve the stability of filaments, and simplify the production
process.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates an embodiment of lighting device.
FIG. 2A illustrates a connection way of filaments.
FIG. 2B is a top view of FIG. 2A.
FIG. 3A illustrates another connection way of filaments.
FIG. 3B is a top view of FIG. 3A
FIG. 4A illustrates an embodiment of filaments.
FIG. 4B is a partial perspective view of filaments.
FIG. 5 illustrates an embodiment of fixing filaments.
FIG. 6 is a flowchart of a manufacturing method of a lighting
device.
DETAILED DESCRIPTION
Firstly, please refer to FIG. 1. FIG. 1 is an exploded perspective
view of lighting device components according to an embodiment of
the present invention.
In the lighting device of FIG. 1, multiple filaments 102 are set in
a cover 101. One end of multiple filaments 102 are fixed to the
upper end of the pillar, and the other ends of multiple filaments
102 are fixed to the base 103. The driver circuit 104 is set in the
heat exchanger cup 105. The heat exchanger cup 105 is set in the
base 106. The base 106 connects to the external power supply such
as standard Edison lamp holder through the electrical foot contact
107 and the side electrode Please refer to FIG. 2A and FIG. 2B.
FIG. 2A shows a connection type of filaments. FIG. 2B is a top view
of FIG. 2A.
In FIG. 2A and FIG. 2B, the top extended electrodes of four
filaments 201, 202, 203, 204 connect as in the drawings, the top
extended electrodes of four filaments 201, 202, 203, 204 are fixed
to the pillar 21, 22. Four filaments 201, 202, 203, 204 are
electrically connected as planned through an annular metallic
support strip extended from the base.
In this embodiment, two of filaments 201, 202, 203, 204 are
electrically connected in series, while others are electrically
connected in parallel. The annular metallic support strip extended
from the base may be cut off according to different connection
types. In other words, the annular metallic support strip as in the
drawings may be cut off according to different connection types of
filaments in the production process, thus to form different
connection types of filaments.
Please refer to FIG. 3A and FIG. 3B. FIG. 3A illustrates another
connection way of filaments. FIG. 3B is a top view of FIG. 3A.
Four filaments 301, 302, 303, 304 of FIG. 3A and FIG. 3B are
electrically connected in series. Compared with the embodiment of
FIG. 2A and FIG. 2B, the connection type of the tops of the
filaments and annular metallic support strip extended from the base
are roughly similar, two embodiments differ in the way of cutting
off annular metallic support strip.
In other words, in these embodiments, the annular metallic support
strips are basically the same, and the base with the same annular
metallic support strip may be produced in large numbers. In the
subsequent production process, a series connection or a parallel
connection are formed by changing the break point of the annular
metallic support strip or changing the connection type between the
filaments and the annular metallic support strip. This method
significantly reduces the production cost.
FIG. 4A shows an embodiment of filaments.
In FIG. 4A, two top extended electrodes 411, 421 are connected to
the filament 41, 42 respectively, each top extended electrode and
filament are manufactured in pair, or each top extended electrode
is fixed to the filament before the top extended electrode is fixed
to the pillar. In this embodiment of FIG. 4A, there is a ring
between the top extended electrodes 411, 421. The ring is put into
the top of the pillar directly, the stability of fixing is
strengthened, and the production process accelerates.
In other words, with this filament structure, people just make the
top extended electrodes of the filaments hang on or weld to the top
of the pillar, then make the bottom extended electrodes 422, 412
connect to the base, such as the annular metallic support strip as
above.
FIG. 4B is a partial perspective view of filaments. The filament
includes a substrate 454. A LED module 452 is mounted on the
substrate, and the phosphor film 451 is set on the substrate. Two
ends of the substrate 454 are formed into electrodes 453.
FIG. 5 shows an embodiment of fixing the filaments.
In FIG. 5, the top extended electrodes 511, 521 of the filaments
51, 52 are fixed together, then the top extended electrodes 511,
521 are put at the top 531 of the pillar 53. In this embodiment,
the top 531 of the pillar 53 is insulated and provided with a
slot.
The present invention provides an improved lighting device
according to the first embodiment of the present invention. The
lighting device includes at least one filament module, a base, at
least one pillar, and a base.
The filament module includes more than two filaments. Each filament
includes a substrate, multiple LED chips, a phosphor film, a top
extended electrode, and a bottom extended electrode. Multiple LED
chips are mounted on the substrate. The phosphor film covers the
substrate and multiple LED chips. The top extended electrode and
bottom extended electrode are connected to two ends of the
substrate respectively. At least part of top extended electrode and
bottom extended electrode are not covered by the phosphor film, and
each top extended electrode of the filaments is fixed together.
The bottom of the pillar is connected to the base. Multiple top
extended electrodes of the filaments of the filament module hang on
the top of the pillar. A driver circuit electrically connects to
multiple bottom extended electrodes of the filaments of the
filament module. The base contains the driver circuit. The base is
used to connect to the power.
In some embodiments, multiple top extended electrodes of the
filaments of the filament module may connect to each other, then
the combination of multiple top extended electrodes connects to the
top of the pillar. In other words, the highest parts of the
filaments may be assembled first, then the highest parts of the
filaments are fixed to the top of the pillar.
In some embodiments, multiple top extended electrodes of the
filaments of the filament module are integrally formed. In this
kind of manufacturing method, the stability and conductivity of the
filament are further improved, and the unnecessary problem of
temperature increase gets better.
In some embodiments, the connection part of the top extended
electrodes of multiple filaments may have a ring. The ring is put
into the top of the pillar.
In some embodiments, the top extended electrode of the filament is
made with a ring, and the top of the pillar is inserted into the
ring. In other words, compared with traditional method of fixing
the stick electrodes by welding, this method further improves the
stability of the filaments.
In some embodiments, the number of the pillar is more than two, and
multiple filaments hang on the tops of the pillars.
In some embodiments, the pillar is a thin piece of metal. For
example, the pillar may be made of iron-nickel alloys with certain
hardness.
In some embodiments, the top of the pillar includes an insulation
part. The insulation part has a support structure used to hold
multiple top extended electrodes of the filaments of the filament
module. In other words, the insulation part avoids a short circuit,
causing by assembly or vibration, when certain filaments are
electrically connected.
In some embodiments, the above-mentioned insulation part may be
made of glass.
In some embodiments, the pillar in the area of insulation part may
be all made of glass.
In some embodiments, the insulation part is made of plastic.
Plastic may further reduce the overall cost. Plastic are easier to
produce a relatively complicated stand, and the stand is used to
support and fix the connection parts of the filaments.
In some embodiments, the support structure is a slot on the top of
the insulation part. In other words, the mounting of the filaments
becomes more stable with gloves, holes, and soon.
In some embodiments, the support part of the pillar is an extended
component set in the insulation part. For example, the support part
may be made out of metal sticks, and the pillar may be made of
plastic or metal. The support part, like metal sticks and so on, is
set in the pillar in the production process of the pillar. In this
way, the stability is improved, and the complexity of assembly is
reduced.
In some embodiments, the extended component is a metal stick. The
extended component includes an inner part and an extended part. The
inner part of the extended component is set in the insulation part.
The extended part of the extended component is stretched away from
the insulation part. The top extended electrodes of multiple
filaments of the filament module hang on the extended part of the
extended component.
In some embodiments, a bottom electrical connection structure
extends from the base. The bottom electrical connection structure
electrically connects to the driver circuit. The bottom extended
electrodes of multiple filaments of the filament module
electrically connect to the bottom electrical connection structure,
and multiple filaments are electrically connected in series or
parallel.
In some embodiments, the bottom electrical connection structure has
an annular metallic strip. By cutting off the annular metallic
strip, multiple filaments are electrically connected in series or
parallel.
In some embodiments, the bottom extended electrodes of multiple
filaments are fixed to the bottom electrical connection structure
and thus to allow the angle between each filament and the pillar to
be more than fifteen degrees.
In some embodiments, an insulator is put over a pair of connection
parts of the top extended electrodes of the filaments, and another
a pair of connection parts of the top extended electrodes of the
filaments are fixed to the pillar over the insulator.
Please refer to FIG. 6. The present invention provides a
manufacturing method of a lighting device according to another view
of the present invention. The manufacturing method includes steps
as follows.
Cut a metal plate to produce the substrate, the top extended
electrode, and the bottom extended electrode of the filament
modules (step 61).
A filament module is provided (step 62). The filament module
includes at least two filaments. The filament includes a substrate,
multiple LED chips, a phosphor film, a top extended electrode, and
a bottom extended electrode. Multiple LED chips are mounted on the
substrate. The phosphor film covers the substrate and multiple LED
chips. The top extended electrode and bottom extended electrode are
connected to two ends of the substrate respectively. At least part
of top extended electrode and bottom extended electrode are not
covered by the phosphor film. Each top extended electrode of the
filaments is fixed together.
One or multiple filament modules are fixed to the pillar of the
lighting device (step 63). The pillar is mounted on the base of the
lighting device.
In some embodiments, this manufacturing method further includes a
producing way of cutting a metal plate to produce the substrate,
the top extended electrode, and the bottom extended electrode of
the filament modules.
According to different embodiments as above, the present invention
makes it possible to decrease the cost with varying degrees,
improve the stability of filaments, and simplify the production
process.
In addition to embodiments as above, the present invention may have
other applications or designs, and as long as they are within the
spirit of the present invention, the various designs still belong
to the scope of the present invention.
* * * * *